Elastic–Plastic Material Deformation and Conveying Value of Twist-Free Turned Surfaces

Counter-surfaces for radial shaft seals are usually finished by infeed grinding to avoid macro twist structures on the surface since they can impose a conveying action on the lubricant. This can lead to either leakage or starved lubrication and subsequent thermal damage depending on the direction of said conveying action. Turning processes can offer a more cost-effective surface finish, but conventional methods cause twist structures, which can impair the leakage prevention of the sealing system. An approach for the production of twist-free surfaces was developed based on new kinematics for turning. However, the surfaces produced with this approach using case hardened specimens made from the steel 16MnCr5 show deviating structural characteristics compared to the kinematic simulation. The causes of this and the resulting influence on the conveying value are the subjects of the research work. For this purpose, in addition to hardened steel, two other materials are considered: the steel 16MnCr5 in the unhardened hot rolled delivery condition and brass as a material with good machinability. The results clearly show that there is a deviation in the machining behavior of the steel materials compared to the kinematic surface simulations, especially in the repeatedly turned areas. This is mainly due to elastic–plastic deformation effects. Despite the actually twist-free surface profile, certain characteristics result in an anisotropic structure, which partially has an influence on the conveying value.